Drywall repair kit and method

ABSTRACT

A repair kit for repairing a damaged area of a workpiece, includes an arbor having an abutment surface, and a cutting member removably coupled to the arbor. The cutting member has a sidewall with a first end and a second end, an end cap coupled to the first end of the side wall and abutting the abutment surface of the arbor, a plurality of cutting elements coupled to the second end of the sidewall, and a retention feature defined by the sidewall. The cutting member is rotatable by the arbor to cut a hole in the workpiece. The retention feature is configured to engage the workpiece as the cutting member cuts the hole to secure the cutting member within the hole.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/133,795, filed on Mar. 16, 2015; and U.S. Provisional PatentApplication No. 62/256,379, filed on Nov. 17, 2015, the entire contentsof all of which are incorporated by reference herein.

FIELD OF INVENTION

The present invention relates to drywall repair kits and, moreparticularly, to drywall repair kits including hole saws.

BACKGROUND

Hole saws are typically used to cut large holes in drywall, wood,plastic or a similar material that would be otherwise difficult for adrill bit. Hole saws cut circular holes in workpieces, resulting inplugs. Therefore, hole saws can cut larger holes that would otherwise bedifficult for a drill bit. A hole saw is sometimes used to cut a hole indrywall where damage has occurred. After the hole is cut, a separatepreformed plug similar in diameter to the hole saw may be inserted intothe hole and plastered over in order to repair the drywall.

SUMMARY

The present invention provides, in one aspect, a repair kit forrepairing a damaged area of a workpiece. The repair kit includes anarbor having an abutment surface, and a cutting member removably coupledto the arbor. The cutting member includes a side wall having a first endand a second end, an end cap coupled to the first end of the side walland abutting the abutment surface of the arbor, a plurality of cuttingelements coupled to the second end of the side wall, and a retentionfeature defined by the side wall. The cutting member is rotatable by thearbor to cut a hole in the workpiece. The retention feature isconfigured to engage the workpiece as the cutting member cuts the holeto secure the cutting member within the hole.

The present invention provides, in another aspect, a method forrepairing a damaged area of a workpiece with a repair kit that includesan arbor and a cutting member removably coupled to the arbor. The arborhas an abutment surface. The cutting member has a side wall, an end capcoupled to a first end of the side wall and abutting the abutmentsurface of the arbor, and a plurality of cutting element coupled to asecond end of the side wall. The method includes rotating the arbor todrive the cutting member about a central axis of the arbor, cutting ahole in the workpiece with the cutting member, and engaging theworkpiece with the cutting member as the hole is cut to secure thecutting member within the hole. The method further includesdisconnecting the arbor from the cutting member, and leaving the cuttingmember in the workpiece to plug the hole.

The present invention provides, in yet another aspect, a plug forplugging a hole in a workpiece. The plug includes a flat disc-shapedbody having a plane and a central axis perpendicular to the plane, and aplurality of resilient members. Each of the resilient members is atleast partially formed by a slot defined in the body that extends froman outer circumference of the body toward the central axis. The plugfurther includes a gripping tooth extending from each of the resilientmembers at the outer circumference of the body. Each of the resilientmembers is movable from an original position to a deflected positionwhen a force is applied to allow the plug to be inserted into the hole.The resilient members return to the original position when the force isremoved such that the gripping teeth engage the workpiece to secure theplug within the hole.

Other features and aspects of the invention will become apparent byconsideration of the following detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a drywall repair kit in accordance withan embodiment of the invention, the drywall repair kit including a holesaw assembly and a guide member.

FIG. 2 is an exploded perspective of the drywall repair kit of FIG. 1.

FIG. 3 is a perspective view of an arbor of the hole saw assembly ofFIG. 1.

FIG. 4 is a perspective view of a cutting member of the hole sawassembly of FIG. 1.

FIG. 5 is a perspective view of the guide member of FIG. 1.

FIG. 6 illustrates a method of repairing a damaged portion of drywallusing the drywall repair kit of FIG. 1.

FIG. 7 is a perspective view of a drywall repair kit in accordance withanother embodiment of the invention, the drywall repair kit including ahole saw assembly and a guide member.

FIG. 8 is an exploded perspective view of the drywall repair kit of FIG.7.

FIG. 9 is another exploded perspective view of the drywall repair kit ofFIG. 7.

FIG. 10 is a perspective view of an auxiliary plug.

FIG. 11 is another perspective view of the auxiliary plug of FIG. 10.

FIG. 12 is a perspective view of an auxiliary plug in accordance withanother embodiment of the invention.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting.

DETAILED DESCRIPTION

FIGS. 1-2 illustrate a drywall repair kit 10 for repairing a puncturedhole or damaged area of a workpiece (e.g., drywall). The illustrated kit10 includes a cutting assembly or hole saw assembly 14 and a guidemember 18. The assembly 14 includes an arbor 22, a pilot drill bit 26,and a cutting member 30. The arbor 22 and the pilot drill bit 26 arecouplable to a drill (not shown) for rotation about an axis of rotationA. In some embodiments, the arbor 22 and the pilot drill bit 26 may becoupled to the drill via a chuck. The drill may be a power drill, amanually turned rotary hand drill or any similar tool capable oftransferring rotational power to the arbor 22. The cutting member 30, orhole saw, is removably coupled to the arbor 22 and is driven by thearbor 22 to cut a circular hole out of the drywall around the damagedarea. The cutting member 30 also acts as a plug and remains in thecircular hole when the arbor 22 and the drill are disconnected.

With reference to FIGS. 2-3, the arbor 22 includes a back piece 34having an abutment face 42. The arbor 22 also defines a bore 38extending through the back piece 34. The bore 38 is concentric with theaxis A. The arbor 22 has drive protrusions 46 that extend outwardly fromthe abutment face 42 parallel to the axis A. In the illustratedembodiment, there are four drive protrusions 46 that are equally spacedcircumferentially around the bore 38 about the axis A. The pilot drillbit 26 is received within the bore 38 of the arbor 22 and extendsoutwardly from the abutment face 42 along the axis A. In alternateembodiments, the arbor 22 and the pilot drill bit 26 may be formed asone piece, and fewer or more drive protrusions 46 may be used.

The arbor 22 also includes a pair of projections 50 extending from arear surface 44 of the back piece 34 opposite the abutment face 42. Theprojections 50 are configured to be manually grasped and turned aboutthe axis A in the absence of a drill or other driving tools. In theillustrated embodiment, the projections 50 include two crescent-shapedprojections extending radially outward from the bore 38. The projections50 are circumferentially spaced apart 180 degrees about the axis A. Inother embodiments, the arbor 22 may include other projectionconfigurations that form grips for manually turning the hole sawassembly 14.

With reference to FIGS. 2 and 4, the cutting member 30 includes anannular side wall 54 and an end cap or back wall 58. The annular wall 54extends from the back wall 58 at a first, proximal end 62 to a second,distal end 66. In some embodiments, the annular wall 54 tapers inwardlytoward the axis A from the first, proximal end 62 to the second, distalend 66. The back wall 58 and the annular wall 54 define a cavity 70. Thesecond end 66 of the annular wall 54 has a series of cutting teeth 74.The annular wall 54 also defines four slots 78 that are equally spacedcircumferentially around the annular wall 54. The teeth 74 and the slots78 are cutting elements that allow the cutting member 30 to functionlike a conventional hole saw.

The illustrated annular wall 54 also defines a retention feature 82. Inthe illustrated embodiment the retention feature 82 includes grooves orthreads 82 extending circumferentially around the annular wall 54. Thethreads 82 are configured to engage the drywall as the cutting member 30cuts into the drywall, thereby securing and retaining the cutting member30 within the circular hole cut by the cutting member 30 so that thearbor 22 may be disconnected and removed. In the illustrated embodiment,the threads 82 are positioned closer to the first end 62 of the annularwall 54 than to the second end 66. In some embodiments, the threads 82may be replaced with any projection extending outwardly from the annularwall 54 to engage the drywall and secure the cutting member 30 withinthe circular hole cut by the cutting member 30.

The back wall 58 defines a central aperture 86 sized to receive thepilot drill bit 26. The back wall 58 also defines drive apertures 90equally spaced around the central aperture 86 and corresponding to thedrive protrusions 46 of the arbor 22. The drive apertures 90 areconfigured to receive the drive protrusions 46 (as shown in FIG. 1). Inalternate embodiments, the drive apertures 90 and the drive protrusions46 may be spaced radially farther from the axis A (i.e., closer to theouter diameter of the back wall 58), as shown in FIGS. 7-9. In furtheralternate embodiments, the drive apertures 90 and the drive protrusions46 may be arranged in any configuration or pattern. In further alternateembodiments, the drive apertures 90 may be blind recesses. In furtheralternate embodiments, the drive protrusions 46 may be located on thecutting member 30, and the drive apertures 90 may be located on thearbor 22. In addition, the illustrated back wall 58 defines throughholes 94 spaced around the central aperture 86. The through holes 94help retain a joint or surfacing compound (e.g., spackle), applied overthe circular hole cut out of the drywall and on the back wall 58 of thecutting member 30.

As previously mentioned, the arbor 22 is coupled to a drill for rotationabout the axis A, and the cutting member 30 is removably coupled to thearbor 22. As shown in FIGS. 1-2, the central aperture 86 and the driveapertures 90 of the cutting member 30 receive the drill bit 26 and thedrive protrusions 46 of the arbor 22 so that the cutting member 30 iscoaxial with the axis A of the arbor 22. Additionally, the back wall 58of the cutting member 30 abuts the abutment face 42 of the back piece34. The back piece 34 extends radially outward past the annular wall 54of the cutting member 30, such that the abutment face 42 of creates anannular flange or lip 96 (FIG. 1) that inhibits the cutting member 30from being driven too deep into the drywall while cutting. The driveprotrusions 46 engage the drive apertures 90 of the cutting member 30 asthe arbor 22 is rotated by the drill, thus driving the cutting member 30about the axis A. The cutting member 30 is held in engagement with thedrive protrusions 46 as force is applied along the axis A in a directionof arrow F (FIG. 1) (e.g., toward the drywall) to drive the cuttingmember 30 deeper into the drywall until cutting is complete. However,the cutting member 30 may be removed from the arbor 22 by axiallysliding the drive protrusions 46 out of the drive apertures 90 and thecutting member 30 off the drill bit 26 in a direction opposite thedirection F (e.g., away from the drywall).

With reference to FIGS. 2 and 5, the guide member 18 is formed as acircular disc with a central projection 88 that extends axiallyoutwardly. The guide member 18 defines a central aperture 92 extendingthrough the projection 88. The central aperture 92 of the guide member18 is sized to provide clearance for the pilot drill bit 26. In theillustrated embodiment, the central aperture 92 is approximately equalin size to the central aperture 86 of the cutting member 30, but may beany size that allows the drill bit 26 to pass therethrough. The guidemember 18 has an outer diameter that is similar to, but no greater than,an inner diameter of the annular wall 54 of the cutting member 30, suchthat the guide member 18 fits within the cavity 70 of the cutting member30. The guide member 18 is configured to be coupled to the drywall, bypressing the projection 88 into the drywall, to cover a damaged area. Inalternate embodiments, the guide member 18 may include teeth, pins,gripping members, adhesive or the like to secure the guide member 18 tothe drywall. In further alternate embodiments, the guide member 18 mayinclude holes configured to receive screws to couple the guide member 18to the drywall. The guide member 18 further defines a plurality of largeholes 98 equally spaced around the central aperture 86. The large holes98 reduce the weight and material of the guide member 18. The holes 98may also be used to view the damaged area through the guide member 18 asthe guide member 18 is coupled to the drywall to make sure the damagedarea is properly covered.

In operation of the drywall repair kit 10, when the cutting member 30 iscoupled to the arbor 22, the drill bit 26 is inserted through thecentral aperture 92 of the guide member 18 to center the cutting member30 on the guide member 18 about the axis A. The cutting member 30 isthen rotated about the axis A until the drive apertures 90 align toreceive the drive protrusions 46. Once aligned, the drill may be poweredto rotate the cutting member 30 about the axis A and begin cutting thehole in the drywall. The guide member 18 fits within the cavity 70 toguide and align the cutting member 30 and keep the cutting member 30straight. Applying force axially along the axis A drives the cuttingmember 30 deeper into the drywall until the annular flange 96 formed bythe back piece 34 abuts the drywall, thereby inhibiting further movementof the assembly 14 into the drywall. As the assembly 14 cuts into thedrywall, the threads 82 of the cutting member 30 engage the drywall tosecure the cutting member 30 within the circular hole in the drywall.Once the cutting member 30 is secured in the circular hole, the drillbit 26 and the drive protrusions 46 are axially withdrawn from thecentral aperture 86 of the cutting member 30 and the drive apertures 90,leaving the cutting member 30 within the circular hole as a plug.

FIG. 6 illustrates a method for repairing a damaged area 304 (e.g., ahole) in drywall 300 using the drywall repair kit 10 of FIGS. 1-5. Instep 1000, the damaged area 304 is observed in the drywall 300. In step1010, the guide member 18 is applied to the drywall 300 to cover thedamaged area 304. The guide member 18 is coupled to the drywall 300 bypressing the projection 88 into the drywall 300. The guide member 18 maybe centered on the damaged area 304 or may be slightly offset relativeto the damaged area 304, depending on the location of studs or otherenvironmental considerations.

In step 1020, the arbor 22 and the cutting member 30 are coupled to adrill 306. The drill bit 26 is aligned in the central aperture 92 of theguide member 18. The drill 306 is then powered so that the cuttingmember 30 cuts a circular cut hole 308 in the drywall 300 around theguide member 18. As the cutting member 30 cuts into the drywall 300, thethreads 82 of the cutting member 30 engage the drywall 300 to secure thecutting member 30 within the hole 308.

In step 1030, the drill 306 and the arbor 22 are axially withdrawn andremoved from the cutting member 30, leaving the hole 308 plugged by thecutting member 30.

In step 1040, the hole 308 and the cutting member 30 are spackled over.The spackle 312 is left to dry. In step 1050, once the spackle 312 hasdried, the spackle 312 is sanded flush with a surface of the drywall300. In step 1060, paint (or other coatings) is applied over the sandedarea of spackle 316 that is covering the cutting member 30 and the hole308. Depending on the type of workpiece being repaired, one or more ofthe steps 1040, 1050, 1060 may be omitted. For example, it may not benecessary to spackle and sand a non-drywall workpiece that is beingrepaired with the kit 10.

The cutting member 30 can have different diameters to allow for repairof larger or smaller damaged areas. For example, in some embodiments,the cutting member 30 may have a diameter of 2.5 inches, and in someembodiments the cutting member 30 may have a diameter of 4 inches,allowing for the repair of damaged areas that have a max width of 2.5inches or 4 inches, respectively. However, the cutting member 30 mayalso be of any diameter between 2.5 inches and 4 inches, any diametersmaller than 2.5 inches, or any diameter larger than 4 inches. The othercomponents of the drywall repair kit 10, such as the arbor 22 and theguide member 18, may be sized accordingly.

FIGS. 7-9 illustrate another drywall repair kit 10 a. With the exceptionof some minor distinctions, the drywall repair kit 10 a of FIGS. 7-9 issubstantially similar to the drywall repair kit 10 of FIGS. 1-5. Likecomponents and features are identified with like reference numerals plusthe letter “a” and will not be described again in detail. The manner ofoperation of the drywall repair kit 10 a of FIGS. 7-9 is identical tothat described above in connection with the drywall repair kit 10 ofFIGS. 1-5. In addition, the method for repairing a damaged area (e.g., ahole) in drywall using the drywall repair kit 10 a of FIGS. 7-9 isidentical to the method for repairing a damaged area using the drywallrepair kit 10 of FIGS. 1-5, as shown in FIG. 6. Therefore, onlydifferences between the two embodiments will be described in detail.

With reference to FIGS. 7-9, the cutting member 30 a includes a singlethread 82 a that extends circumferentially around the annular wall 54 aof the cutting member 30 a. Similar to the threads 82 of the cuttingmember 30 of FIGS. 1, 2, and 4, the thread 82 a engages the drywall asthe cutting member 30 a cuts into the drywall, thereby retaining thecutting member 30 a within the circular hole cut by the cutting member30 a once the arbor is removed. The single thread 82 a on the cuttingmember reduces the possibility of the cutting member 30 a grinding intothe drywall compared to a cutting member with multiple threads.

With continued reference to FIGS. 7-9, the drive apertures 90 a of thecutting member 30 a are spaced farther away radially from the axis A,nearer the annular wall 54 a. The corresponding drive protrusions 46 aof the arbor 22 a are also spaced farther away radially from the axis A.Additionally, although not shown, the drywall repair kit 10 a of FIGS.7-9 may include a pilot drill bit similar to the pilot drill bit 26 ofFIGS. 1 and 5.

FIGS. 10-11 illustrate an auxiliary plug 100 that may be included in thedrywall repair kit 10 of FIGS. 1-5 and used to plug holes cut in thedrywall by the cutting member 30 or a similarly sized hole saw. Theauxiliary plug 100 is typically used when an obstruction (e.g., a stud)inhibits the cutting member 30 from being fully inserted into the hole,and thus, flush with the surface of the drywall. The auxiliary plug 100,may be part of the drywall repair kit 10 or an independent componentthat is used separately or in combination with other hole saws ordrywall repair kits. Although described with reference to, and as partof, the drywall repair kit 10 of FIGS. 1-5, the auxiliary plug 100 mayalso be included in, or used with, the drywall repair kit 10 a of FIGS.7-9.

The auxiliary plug 100 includes a generally flat disc shaped body 104having a central axis B. The body 104 defines a pair of slots 108 thateach extend from an outer circumference 106 of the body 104 to form apair of flexible resilient members 112 on the body 104. In theillustrated embodiment, the slots 108 are generally L-shaped, but mayalternatively have other shapes or configurations. Specifically, each ofthe illustrated slots 108 has a first portion 108A that extends from theouter circumference 106 generally towards the center of auxiliary plug100, and a second portion 108B that extends from an end of the firstportion 108A towards the outer circumference 106 to form an “L” shape.Each of the resilient members 112 has a flexible portion 122 between anend of the second portion 108B of the slot 108 and the outercircumference 106. The flexible portions 122 connect each of theresilient members 112 to the rest of the body 104. The resilient members112 and the pair of slots 108 are configured with the flexible portion122 to allow the resilient members 112 to flex radially inwards.

In the illustrated embodiment, the resilient members 112 each have acylindrical projection 116 axially extending from the body 104. Thecylindrical projections 116 each have a recess 120 for receiving, forexample, a thumb and a finger of a user, respectively, for squeezing theresilient members 112 radially inward. In particular, a user can inserthis/her thumb and finger into the recesses 120 and then squeeze his/herthumb and finger together. This action causes the resilient members 112to flex or bend about the flexible portions 122 radially inwards towardthe center of the body 104 (e.g., in the direction of arrows C in FIG.11). As the resilient members 112 move toward the center, the members112 collapse the slots 108 and reduce the outer diameter of the body104.

The illustrated auxiliary plug 100 further includes three gripping teeth124 extending from the outer circumference 106 of the auxiliary plug100. In the illustrated embodiment, the gripping teeth 124 are evenlycircumferentially spaced around the outer circumference 106 (e.g., about120 degrees apart about the central axis of the body 104). Each of theresilient members 112 includes at least one of the gripping teeth 124adjacent the corresponding slot 108 on the outer circumference 106.Another one of the gripping teeth 124 is located on the outercircumference 106 equidistant from the gripping teeth 124 on theresilient members 112. In addition, similar to the cutting member 30,the illustrated body 104 defines through holes 128. The through holes128 help to retain spackle applied over the circular hole cut out of thedrywall and the body 104 of the auxiliary plug 100.

The auxiliary plug 100 may have different diameters to allow for repairof larger or smaller damaged areas. The diameters may correspond to thediameter of the cutting member 30 or another hole saw. The diameter maybe the same as the cutting member 30 or slightly larger to provide for atight fit within the hole in the drywall cut out by the cutting member30. For example, the auxiliary plug 100 may have a diameter of about 2.5inches or about 4 inches, allowing for the repair of damaged areas thathave a max width of 2.5 inches or 4 inches, respectively. However, theauxiliary plug 100 may also be of any diameter between 2.5 inches and 4inches, or of any diameter smaller than 2.5 inches or larger than 4inches.

In operation, the auxiliary plug 100 is typically used when the cuttingmember 30 cannot fully be received within the hole cut in the drywalldue to an obstruction such that the back wall 58 of the cutting member30 is not flush with the surface of the drywall. The obstruction istypically a material that is too hard to be cut by the cutting member 30(e.g., a wooden or metal stud), but in some instances the obstructionmay be undesirable to cut for structural or aesthetic reasons. Once thehole has been cut in the drywall, the cutting member 30 is removed fromthe hole along with the guide member 18. If the threads 82 of thecutting member 30 are engaged with the drywall, the cutting member 30 isremoved by rotating the cutting member 30 in a direction opposite thecutting direction to disengage the threads 82.

After the cutting member 30 is removed, a user selects an auxiliary plug100 of appropriate size for the hole. The user then inserts a thumb anda finger into a corresponding one of the recesses 120 of the resilientmembers 112 of the auxiliary plug 100. The resilient members 112 aresqueezed together such that the resilient members 112 deflect inwardlytowards one another to reduce the diameter of the auxiliary plug 100.The diameter of the auxiliary plug 100 is reduced in order to fit withinthe hole. This is due to the diameter of the auxiliary plug 100 beingapproximately the same as, or slightly larger than, the diameter of thecutting member 30. The auxiliary plug 100 is then inserted into the holein the drywall. The resilient members 112 are then released, allowingthe flexible portions 122 to spring back, such that the resilientmembers 112 move towards their original position. As the resilientmembers 112 deflect radially outward, the outer circumference 106 andthe gripping teeth 124 engage the hole in the drywall to secure theauxiliary plug 100 within the hole.

The method of using the drywall repair kit 10 shown in FIG. 6 is similarto a method that includes and uses the auxiliary plug 100. Therefore,only the differences between the methods will be explained in detail.Step 1000, step 1010, and step 1020 remain the same as the methoddescribed above in which the auxiliary plug 100 is not used. Step 1030is also similar; however, the hole saw 30 and the guide member 18 areremoved once the hole 308 is made in the drywall 300. In an additionalstep, between step 1030 and step 1040, the auxiliary plug 100 isinserted into the hole 308 as described in detail above. Once theauxiliary plug 100 is secured within the hole 308, the auxiliary plug100 and the hole 308 are spackled over and left to dry, similar to step1040 in which the cutting member 30 remains in the hole 308. Step 1050and step 1060 remain the same, in which the spackle 312 is sanded flushwith the surface of the drywall 300 before applying paint.

FIG. 12 illustrates another auxiliary plug that may be included in thedrywall repair kit 10 of FIGS. 1-5 and used to plug holes cut in thedrywall by the cutting member 30 or a similarly sized hole saw. Theauxiliary plug 200 is typically used when an obstruction (e.g., a stud)inhibits the cutting member 30 from being fully inserted into the holeand flush with the surface of the drywall. The auxiliary plug 200 may bepart of the drywall repair kit 10 or an independent component that isused separately or in combination with other hole saws or drywall repairkits. Although described with reference to, and as part of, the drywallrepair kit 10 of FIGS. 1-5, the auxiliary plug 100 may also be includedin, or used with, the drywall repair kit 10 a of FIGS. 7-9.

With reference to FIG. 12, the auxiliary plug 200 includes a generallyflat disc-shaped body 204 having a plane and a central axis Bperpendicular to the plane in a center of the body 204. The body 204 hasan outer circumference 206. The auxiliary plug 200 further includesflexible resilient members 212 circumferentially spaced evenly about thecenter axis (e.g., about 30 degrees apart about the central axis of thebody 204). In the illustrated embodiment, the plug 200 includes twelveflexible resilient members 212, but may alternatively include fewer ormore flexible members 12. Each of the resilient members 212 is definedin the body 204 by a pair of slots 208 that extend from the outercircumference 206 of the body 204 generally towards the center of thebody 204. Each of the resilient members 212 is connected to the body 204by a flexible portion 222. The resilient members 212 are configured withthe flexible portions 222 to allow the resilient members 212 to flex outof the plane with the remainder of the body 204. Specifically, as aforce is applied to each of the resilient members 212, the resilientmember 212 deflects to a deflected position in which the resilientmember 212 is deformed out of the plane of the body 204 generallytowards the central axis B (e.g., in the direction of arrow D in FIG.9). When the force is removed, the resilient member 212 springs back tothe original position, in which the resilient member 212 lies in theplane of the body 204.

In the illustrated embodiment, each of the resilient members 212 has agripping tooth 224. Each gripping tooth 224 extends radially outward ata distal end of each of the resilient members 212 so as to protrude fromthe outer circumference 206 of the body 204. In addition, similar to theauxiliary plug 100 of FIGS. 10-11, the illustrated body 204 definesthrough holes 228. The through holes 228 help to retain spackle appliedover the circular hole cut out of the drywall and the body 204 of theauxiliary plug 200.

Similar to the auxiliary plug 100 of FIGS. 10-11, the auxiliary plug 200of FIG. 12 may have different diameters to allow for repair of larger orsmaller damaged areas. The diameters may correspond to the diameter ofthe cutting member 30 or another hole saw. The diameter may be the sameas the cutting member 30 or slightly larger to provide for a tight fitwithin the hole in the drywall cut out by the cutting member 30. Forexample, the auxiliary plug 200 may have a diameter of about 2.5 inchesor about 4 inches, allowing for the repair of damaged areas that have amax width of 2.5 inches or 4 inches, respectively. However, theauxiliary plug 200 may also be of any diameter between 2.5 inches and 4inches, or of any diameter smaller than 2.5 inches or larger than 4inches.

In operation, similar to the auxiliary plug 100 of FIGS. 10-11, theauxiliary plug 200 is used when the cutting member 30 is unable to actas a plug, for example, when the cutting member 30 cannot be fullyreceived within the hole cut in the drywall. Once the cutting member 30is removed from the hole, a user selects an auxiliary plug 200 ofappropriate size for the hole. The auxiliary plug 200 is then alignedwith the hole and inserted into the hole in the drywall by pushing onthe auxiliary plug 200, thereby applying an axial force generally alongthe central axis. As the body 204 of the auxiliary plug 200 is insertedinto the hole, the teeth 224 extending from each of the resilientmembers 212 engage the drywall around the edge of the hole causing theresilient members 212 to flex and deflect away from the body 204 toallow the auxiliary plug 200 to be inserted into the hole. Once theauxiliary plug 200 is fully inserted into the hole, the resilientmembers 212 spring back to their original position, such that theresilient members 212 lie in the plane of the body 204 and the teeth 224of the resilient members 212 engage the drywall to secure the auxiliaryplug 200 within the hole.

The method of repairing a damaged area (e.g., a hole) in drywall usingthe drywall repair kit 10, 10 a in combination with the auxiliary plug200 of FIG. 12 is identical to the method for repairing a damaged areausing the drywall repair kit 10, 10 a with the auxiliary plug 100 ofFIGS. 10-11, as described above. One simply uses the auxiliary plug 200of FIG. 12 in place of the auxiliary plug 100 of FIGS. 10-11.

Additionally, each of the components of the drywall repair kit 10 ofFIGS. 1-5, the drywall repair kit 10 a of FIGS. 7-9, and the auxiliaryplugs 100, 200 of FIGS. 10-12 may be formed out of plastic, composites,metal or any other suitable material for cutting drywall. It should benoted that the individual components may be formed out of differentmaterials. For example, the cutting member 30 may be formed out ofmetal, while the auxiliary plugs 100, 200 may be formed out of plastic.Additionally, although, the present application specifically refers torepairing drywall, it should be readily apparent that the kits 10, 10 amay also be used to repair other types of workpieces, such as wood,composite material or the like.

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe scope and spirit of one or more independent aspects of the inventionas described. Various features and advantages of the invention are setforth in the following claims.

What is claimed is:
 1. A repair kit for repairing a damaged area of aworkpiece, the repair kit comprising: an arbor having an abutmentsurface; and a cutting member removably coupled to the arbor, thecutting member including a side wall having a first end and a secondend, an end cap coupled to the first end of the side wall and abuttingthe abutment surface of the arbor, a plurality of cutting elementscoupled to the second end of the side wall, and a retention featuredefined by the side wall, the cutting member being rotatable by thearbor to cut a hole in the workpiece, wherein the retention feature isconfigured to engage the workpiece as the cutting member cuts the holeto secure the cutting member within the hole.
 2. The repair kit of claim1, wherein the retention feature includes a thread that extendscircumferentially around the side wall.
 3. The repair kit of claim 2,wherein the thread is positioned closer to the first end of the sidewall than to the second end of the side wall
 4. The repair kit of claim1, wherein the cutting member defines a plurality of drive apertures inthe end cap, wherein the arbor includes a plurality of drive protrusionsextending from the abutment surface, and wherein the plurality of driveapertures receives the plurality of drive protrusions such that thearbor rotationally drives the cutting member.
 5. The repair kit of claim1, wherein the arbor includes a grip extending from a surface of thearbor opposite the abutment surface for manually turning the arbor. 6.The repair kit of claim 1, further comprising a pilot drill bit coupledto the arbor, wherein the pilot drill bit extends from the abutmentsurface along a central axis of the arbor, and wherein the end cap ofthe cutting member defines a central aperture that provides clearancefor the pilot drill bit.
 7. The repair kit of claim 1, wherein theabutment surface of the arbor extends radially beyond the end cap of thecutting member to form a lip.
 8. The repair kit of claim 1, furthercomprising a guide member couplable to the workpiece over the damagedarea, wherein the guide member is sized to be received within a cavitydefined by the side wall of the cutting member.
 9. The repair kit ofclaim 8, wherein the guide member includes a central projection thatextends axially away from the end cap of the cutting member, and whereinthe central projection is pressable into the workpiece to connect theguide member to the workpiece.
 10. The repair kit of claim 9, furthercomprising a pilot drill bit coupled to the arbor, wherein the pilotdrill bit extends from the abutment surface along a central axis of thearbor, and wherein the central projection of the guide member defines anaperture that provides clearance for the pilot drill bit.
 11. A methodfor repairing a damaged area of a workpiece with a repair kit includingan arbor and a cutting member removably coupled to the arbor, the arborhaving an abutment surface, the cutting member having a side wall, anend cap coupled to a first end of the side wall and abutting theabutment surface of the arbor, and a plurality of cutting elementscoupled to a second end of the side wall, the method comprising:rotating the arbor to drive the cutting member about a central axis ofthe arbor; cutting a hole in the workpiece with the cutting member;engaging the workpiece with the cutting member as the hole is cut tosecure the cutting member within the hole; disconnecting the arbor fromthe cutting member; and leaving the cutting member in the workpiece toplug the hole.
 12. The method of claim 11, wherein the abutment surfaceof the arbor extends radially beyond the end cap of the cutting memberto form a lip, and wherein cutting the hole includes driving the cuttingmember axially into the workpiece until the lip engages the workpiece.13. The method of claim 11, wherein the cutting member defines aplurality of drive apertures in the end cap, wherein the arbor includesa plurality of drive protrusions extending from the abutment surface,wherein rotating the arbor to drive the cutting member includesreceiving the plurality of drive protrusions in the plurality of driveapertures, and wherein disconnecting the arbor from the cutting memberincludes withdrawing the plurality of driving protrusions from theplurality of drive apertures.
 14. The method of claim 11, wherein thecutting member includes a thread extending circumferentially around theside wall, and wherein engaging the workpiece with the cutting memberincludes engaging with the workpiece with the thread as the cuttingmember cuts the hole.
 15. The method of claim 11, further comprising:applying spackle over the hole and the cutting member to create aspackled area; sanding the spackled area to be flush with an adjacentsurface of the workpiece; and applying a coating to the spackled area ofthe workpiece.
 16. The method of claim 11, further comprising: selectinga guide member sized to sufficiently cover the damaged area of theworkpiece; positioning the guide member over the damaged area; andguiding the cutting member to cut the hole at the damaged area of theworkpiece using the guide member.
 17. The method of claim 16, whereinguiding the cutting member includes receiving the guide member within acavity defined by the side wall of the cutting member.
 18. The method ofclaim 16, wherein the guide member includes a central projection thatextends axially away from the end cap of the cutting member, and whereinpositioning the guide member over the damaged area includes pressing thecentral projection into the workpiece.
 19. A plug for plugging a hole ina workpiece, the plug comprising: a flat disc-shaped body having a planeand a central axis perpendicular to the plane; a plurality of resilientmembers, each of the resilient members at least partially formed by aslot defined in the body and extending from an outer circumference ofthe body toward the central axis; and a gripping tooth extending fromeach of the resilient members at the outer circumference of the body,wherein each of the resilient members is movable from an originalposition to a deflected position when a force is applied to allow theplug to be inserted into the hole, and wherein the resilient membersreturn to the original position when the force is removed such that thegripping teeth engage the workpiece to secure the plug within the hole.20. The plug of claim 19, wherein each of the plurality of resilientmembers is flexed radially inward towards the central axis when theforce is applied to reduce a diameter of the body.
 21. The plug of claim19, wherein the slot associated with each resilient member has a firstportion that extends from the outer circumference towards the centralaxis and a second portion that extends from the first portion towardsthe outer circumference to define an L-shaped slot.
 22. The plug ofclaim 19, wherein each of the plurality of resilient members is flexedout of the plane when the force is applied.